ICS Ice Cleaning Systems GmbH • Rudolf-Diesel-Ring 2a • 82054 Sauerlach • Germany Telephone +49 8104 909480 • Telefax +49 8104 9094829 • Email: info@ics-dryice.de • Internet: www.ics-dryice.de

Opera

ting m

anual IC

02

0

2

Content Your dry-ice blasting unit 3

Introduction & Copyright 4

Process description 5

Technical data 6

Safety equipment 7

Operation of the IC 020 8

Connection of the IC 020 9/10

Operation of the blasting gun 11

Start-up and shutdown 12

Filling the hopper 13

Safety precautions 14/15

Transport 16

Repair & warranty 16

Terms of warranty 17

Requirements for the compressed air 17

Maintenance 17

Maintenance schedule 18

Troubleshooting 19

Drawing 20

Pneumatic plan 21

Safety data sheet for dry-ice 22

Declaration of conformity 23

3

Your dry-ice blasting unit

Typ

Model

Modele

Nr.

No.

No.

Gewicht

Weight

Poids

Druck max.

Pressure max.

Pression max.

Baujahr

Manuf. date

Annee de

fabrication

Your contact to ICS: ICS Ice Cleaning Systems GmbH Rudolf-Diesel-Ring 2a

82054 Sauerlach Phone: +49 8104 909480 Fax: +49 8104 9094829

Email: info@ics-dryice.de

4

Introduction & Copyright

These operating instructions serves as explanation for a safe and undisturbed operation of the IC 020 dry-ice blasting unit.

All individuals who are operating the blasting unit have to read and understand completely the operator’s manual, before using it.

Please keep these operating instructions always close at hand.

Disregarding the procedures described in the operator’s manual may lead to serious consequences for units and persons. The operator has to adhere strictly to the described procedure. Any changing in the operating procedure requires the written approval of ICS

Ice Cleaning Systems GmbH.

The manufacturer of this unit takes no responsibility of damages to the unit or caused by

the unit in case of: • Disregarding these operating instructions

• Improper use or handling of IC 020 • Repair and maintenance by unauthorised persons

• Installation and replacement of non-original ICS parts • Violation of requirements for the compressed air

ICS Ice Cleaning Systems GmbH retains the copyright on the operator’s manual.

These operating instructions is intended for operators and supervision personnel. It contains regulations, drawings and instructions which shall be neither completely used

nor disclosed to third parties without express written consent. Improvement suggestions for the unit or for the operator’s manual may be communicated to ICS Ice Cleaning Systems GmbH.

The drawing of the illustrated blasting unit may differ in details from the actual product

range.

5

Process description

The IC 020 dry-ice blasting unit

operates with dry-ice pellets (ø 1.5

mm), manufactured by compressing

snow-like solid CO2. The pellets are blasted with compressed air on the

surface to be cleaned. The dirt on the surface will get quick frozen and will chip off by its different coefficients of

expansion. The CO2 ice sublimates in the moment of impact from a solid to a

gaseous state. And as residue remains only the initial dirt.

The dry-ice pellets (ø 1.5 mm) from the

hopper are sucked by a dosing system,

transported through the feed hose and accelerated in the blasting nozzle. Thus,

the pellets can achieve sonic speed (depending on pressure and blasting nozzle).

6

Technical data of the IC 020

Length 528 mm

Width 296 mm

Height 336 mm

Weight 18 kg, including hose package

Filling capacity of dry-ice 4 kg standard

Consumption of dry-ice 18-25 kg/h

Required operating pressure min. 4 bar – max. 10 bar

Consumption of compressed

air

0.3 m³/min – 0.8 m³/min, depending on the

chosen combination of nozzle and operating pressure

Requirements for the compressed air

The compressed air has to be clean, dry and oil-free, meaning free of foreign bodies.

Minimum requirements for the quality of compressed air according to ISO 8573-

1:2010 [1:4:1]

Compressed air supply Quick coupling NW 7.2 (standard) ISO 4414 / EN 983

Noise emission 65-94 dB(A), depending on the blasting pressure, combination of nozzles and the

surface of the object to be cleaned

7

Safety equipment

Before starting work, care should be taken for the kind of dirt and object to be cleaned, so that you can optionally take further safety measures, e. g. full protection.

For a safe operation of a dry-ice blasting unit you always need the following protecting equipment:

1. Safety glasses 2. Ear protection

3. Long-sleeved working suit 4. Protective gloves

5. Dust mask 6. Safety shoes

Caution!

In poorly ventilated areas, the elevated concentration of CO2 can lead to breathing difficulties and suffocation. Therefore,

you should always care for sufficient fresh air in confined spaces (exhaust and fresh air).

When cleaning in silos, tanks or confined spaces, also ensure adequate air circulation or use, in addition, a breathing mask,

which has an activated carbon filter interposed in the air supply line.

8

Operation of the IC 020

The emergency shut-down button interrupts all functions of the unit immediately.

Emergency

shut-down

Caution! Despite the use of the emergency shut-down button the unit is

still under pressure!

Safety instructions

9

Connection of the IC 020 Connections and components of the front side

The blasting hose package including the control line is connected firmly with the IC 020.

Blasting hose

10

Connection of the IC 020

Connections and components of the back side

Connect the compressed air hose with the quick coupling NW 7.2 by pressing the

hose coupling onto the nipple until it clicks. To remove, press the coupling of the non-pressurised compressed air hose towards the machine and pull the outer ring towards you.

Transport handle

Quick coupling NW 7.2

Compressed air

11

Operation of the blasting gun

Pressure control

valve

To activate the blasting gun, pull the trigger from the handle. The blasting process will stop by releasing the trigger, it will move in start position by itself. By closing

the ice control valve the ice supply will be interrupted, so that you can carry out the final dry of the blasted surface only with compressed air. With the pressure control valve you set the desired blasting pressure directly on the gun. The IC 020 has a time lag of about 2 seconds to eliminate residual ice from the dosing system and thus avoid icing.

Trigger

Ice control valve

Caution! Always make sure you have the gun safe and firmly in the hand

in order not to endanger yourself and others.

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Start-up For the start-up of the IC 020 proceed as follows:

1. Check before each start-up if the pressure control valve is closed.

2. Connect the compressed air hose first with the quick coupling NW 7.2 on the

rear of the blasting unit and then with the compressed air source.

3. Check the hose package and the gun for damages.

4. Open the compressed air source slowly

5. Aim the blasting gun towards the floor and press it for about 10 sec. to release the residual moisture from the system.

Now fill the dry-ice hopper with dry-ice pellets and close the cover to prevent foreign bodies entering the hopper.

6. Now the IC 020 is ready for use.

Shut-down After finishing the blasting work proceed as follows:

1. Blast the dry-ice hopper until empty.

2. Close the compressed air source.

3. Actuate the gun to release the residual compressed air.

4. Separate the compressed air hose from the unit.

5. Close the pressure control valve.

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Filling the hopper Open the lid and fill the hopper with 1.5 mm pellets

(maximum 4 kg) and close the lid.

Insulated dry-ice hopper

Lid

14

Safety precautions page 1 of 2

The safety precautions are important to you and other people involved, and for a

hazard-free use of the IC 020 blasting unit.

Before working on the IC 020 the unit has to be depressurised.

Always place compressed air hoses so that they pose no threat. Only use compressed air hoses without any sign of damage. Open the compressed air source slowly after successful connection with the unit. At this point the IC 020 is pressurised and shall under no circumstances be left unattended.

When blasting in confined spaces sufficient supply of fresh air must be ensured; CO2 is odourless and tasteless.

It reduces the oxygen content of the breathing air. Failure to do so can be fatal!

The maximum allowable concentration (=maximum allowable concentration in 8 hours of work) is of 5.000 ppm. A CO2-concentration of 8-10% (v/v) in the air is

deadly.

Note: 1 kg dry-ice pellets sublimates into about 0.5 m³ CO2 when blasting

When working with dry-ice, the safety data sheet of the supplier must be observed. Make sure that only dry-ice pellets are filled

into the dry-ice hopper. Always use safety gloves when handling dry-ice, because it can cause cold burns.

The dry-ice temperature is -79°C

See the Safety Data Sheet at the end of these operating instructions.

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Safety precautions page 2 of 2

Please avoid storing the dry-ice pellets longer than 15 minutes in the dry-ice hopper to avoid freezing of the IC 020.

Hopper and dosing system may freeze, if remaining ice stays in the

hopper. Therefore, the hopper has to be blasted empty or the remaining dry-ice has to be removed by hand. Mechanical interventions for removing the dry-ice pellets are prohibited, as they may damage the

dosing system.

Due to the high speed of the pellets serious injury may result. Therefore it must never be blasted towards people or animals. Never reach into the blast - high risk of injury!

The workspace has to be closed where necessary, not to endanger third parties. The IC 020 may only be operated by qualified personnel and after a thorough

training. The user must operate the IC 020 only in flawless condition and repair any damages

immediately (see page 18).

For the operation of the IC 020 always apply in addition the local safety and

accident prevention regulations.

High electrostatic charges may occur. Always make sure that the object to be cleaned is grounded and remains so for the duration of the

cleaning. IC 020 is grounded continuously from the gun through the blasting hose package to the earthing roll.

The user should always wear safety shoes class S2 or higher in order to protect himself from the electrostatic charge.

People who wear a pacemaker are not permitted

to work with an IC 020.

Caution! The procedure should not be used in areas with potentially

explosive air mixtures.

16

Transport For easy transport from one place of work to another within your company, please use the transport

handle.

For further transport of the IC 020 with a shipping company, we recommend to use the shipping carton included in the scope of supply.

Repair & warranty

Possibly required repairs during the warranty period are coordinated in advance with ICS Ice Cleaning Systems GmbH.

Replacement parts covered by the warranty will be replaced either in our company or

shipped to you. Transport, travel and accommodation costs, together with costs for disassembly and reassembly will be borne by the client.

In order to assess the warranty, the replacement part or the machine has to be sent to ICS Ice Cleaning Systems GmbH.

Please note that all works including inspection and maintenance works,

especially the works on the safety devices, must be carried out solely by an ICS technician or by a person who can provide proof of receiving a special

training on the machines and the equipment of ICS Ice Cleaning Systems GmbH.

17

Terms of warranty Your warranty will be lost if:

• the IC 020 is used improperly. • not original parts are used.

• works are carried out on the IC 020 by unauthorized persons. • other blasting media are used as dry-ice.

• the requirements for the compressed air are not complied with.

All unauthorized modifications of the IC 020 are prohibited! The period of warranty is of 12 months from the delivery.

Requirements for the compressed air

For an efficient blasting result, the compressed air to be used is of outermost importance. The compressed air should be dry, clean, oil-free and free of foreign

bodies. We recommend that the minimum requirements for the quality of the compressed air

comply with ISO 8573-1: 12010 [1:4:1], i. e.

Particle = class 1 = 0.1 mg/m³

Water = class 4 = DTP 3°C Oil = class 1 = 0.01 mg/m³

The pressure range of the IC 020 is from 1 - 10 bar and the amount of air from 0.3

– 1.5 m³/min.

Maintenance Thanks to the clear structure of the IC 020, maintenance costs are low.

The IC 020 must be maintained regularly, but not later than 12 months. See the annual inspection plate (see page 8).

We recommend you to enter into a service agreement with ICS Ice Cleaning Systems GmbH or with an authorized ICS Partner.

18

Maintenance schedule for IC 020 every 12 months

1. General visual inspection of housing, welding seams, chassis, wheels, screw joints

2. Complete exterior and interior cleaning if required

3. Check the operation of the inlet pressure valve 4. Filter/regulator combination, replace filter, clean and re-adjust

5. Check pneumatic control elements, check for leaks and replace sound

absorbers 6. Check compressed air inlet filter, filter cartridge and automatic drain, or renew

7. Check compressed air cylinder for operation, leaks and tightness

8. Check complete ice dosing system for wear, operation and leak tightness

9. Check hopper for operation and leak tightness

10. Check hose package for wear, operation and leak tightness (perform pressure test)

11. Check connection elements, connectors and pneumatic couplings for damage,

operation and safety 12. Check blasting gun for operation and safety

13. Check existing blasting nozzles for wear and cracks

14. Pressure test and security test

15. Operation test

16. Blasting test

17. Renew inspection and maintenance plate

19

Troubleshooting

Problem Description Corrective action

Unit does not turn on Emergency stop is

engaged

Release the emergency stop

button by turning it to the right.

Unit does not start After triggering the gun nothing happens.

Check the compressed air supply.

No air at the gun Unit is running, but there

is no air.

Check the pressure control

valve and open it.

No ice is coming out

After triggering the gun

only air is coming out, but no ice.

Fill the hopper with ice. Check

the ice control valve and open it.

Unit is blocked During blasting the hose

package get blocked.

Blasting pressure and blasting

pipe are not perfectly matched. Press the blasting pipe shortly

on the floor while triggering the gun to free the system by causing air backflow.

20

21

Operating manual according to art. 14of the Ordinance on Hazardous Substances

Operating area: Working place:

Status: May 2012 (based on SDB 4/ 2005)

Identification of hazardous substance Dry ice

Other designation: Carbon dioxide – in frozen state CAS no.: 124-38-9 EU index no.:204-696-9

Aggregate state: solid Colour: white Odour: inodorous Flash point: Boiling point:-78.5°C Melting point: -56.6°C

Dangers for people and environment Risk of frostbite development (-78°C) at skin contact Risk of suffocation because of the sublimated vapours (from 1 litre of dry ice result 460 litres of gas) Loss of mobility and consciousness The gas released through evaporation is heavier than air and can accumulate in lower spaces.

First aid measure and rules of conduct Protective measures: - Avoid contact of the product with skin and eyes;

- During usage, ensure proper ventilation in the room;

- During the shredding operation, avoid dispersion of the chips;

- Do not transport with elevator if the elevator is being used by people;

- Avoid protrusion of the gas released by evaporation in the sewerage or in lower areas.

Eye protection: Wear goggles with tight-closing system.

Hand protection: Wear protective gloves made of leather or

low temperature resistant gloves

Suitable extinguishing agents According to the conditions; carbon dioxide does not

burn

Storage: - not to be stored in basements and unventilated

spaces;

- not to be stored in gas-tight containers (risk of bursting because of high pressure).

First aid measures Injured persons have to be transported out of the danger area, using protection means, proper ventilation has to be ensured, in case of high concentration levels, a self-contained breathing apparatus has to be used.

Administering first aid General information

After inhalation Ensure proper ventilation, in case a person becomes unconscious, the victim should be positioned in a stable side position, in case of respiratory arrest administer artificial respiration, seek medical assistance.

In case of skin contact In case of frostbites, rinse for 15 minutes with lukewarm water. In case of eye contact Rinse eyes for at least 15 minutes, afterwards see an

ophthalmologist. After swallowing Drink plenty of water, seek medical assistance.

Appropriate disposal The dry ice residues can be stored outdoors and left to evaporate, but only under strict supervision.

For additional information, contact the Labour Protection Department.

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EC DECLARATION OF CONFORMITY in compliance with the Machine Directive 2006/42/EC dated 17 May 2006, Annex II A

We hereby declare that the machine specified below complies in its design and construction

and in the version marketed by us with the basic safety and health requirements of the EC Directive 2006/42/EC. Any changes to the machine unauthorized by us shall invalidate this declaration.

Product: dry ice blasting unit

Type: IC 020 / IC 110 / IC 110E / IC 310 / IC 310S

Manufacturer: ICS ice cleaning systems s.r.o. Robotnícka 2192, Považská Bystrica, Slovak Republic

Phone: +421 42 4261 135 Email: info@ics-dryice.de

Web: www.ics-dryice.de

It is declared the compliance with other directives/regulations applicable to the product:

2006/42/EC - Machine Directive

2006/95/EC - Low Voltage Directive

EMC Directive (2004/108/EC) dated 15 December 2004

Applied harmonized standards in particular: DIN EN 12100 Safety of machinery - Basic concepts, general principles for design -

basic terminology, methodology, risk assessment DIN EN 60204-1 Safety of machinery - Electrical equipment of machines, Part 1:

General requirements DIN EN ISO 13849-1: Safety of machinery - Safety-related Parts of Control Systems

Representative for the technical documentation: Eng. L’udovit Bakala, PhD.

Place/Date: Považská Bystrica, Slovak Republic, 01.10.2015